Shear Strength Optimization of Laser-Joined Polyphenylene Sulfide-Based CFRTP and Stainless Steel
A thermosetting plastic and stainless steel were joined by the fiber laser with and without polyphenylene sulfide (PPS) additive. Its microstructure, interface morphology, and shear strength were investigated. Исследовано соединение термопласта, армированного углеродным волокном, и нержавеющей стали...
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| Zitieren: | Shear Strength Optimization of Laser-Joined Polyphenylene Sulfide-Based CFRTP and Stainless Steel / L.Y. Sheng, F.Y. Wang, Q. Wang, J.K. Jiao // Проблемы прочности. — 2018. — № 5. — С. 153-160. — Бібліогр.: 20 назв. — англ. |
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| author | Sheng, L.Y. Wang, F.Y. Wang, Q. Jiao, J.K. |
| author_facet | Sheng, L.Y. Wang, F.Y. Wang, Q. Jiao, J.K. |
| citation_txt | Shear Strength Optimization of Laser-Joined Polyphenylene Sulfide-Based CFRTP and Stainless Steel / L.Y. Sheng, F.Y. Wang, Q. Wang, J.K. Jiao // Проблемы прочности. — 2018. — № 5. — С. 153-160. — Бібліогр.: 20 назв. — англ. |
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| container_title | Проблемы прочности |
| description | A thermosetting plastic and stainless steel were joined by the fiber laser with and without polyphenylene sulfide (PPS) additive. Its microstructure, interface morphology, and shear strength were investigated.
Исследовано соединение термопласта, армированного углеродным волокном, и нержавеющей стали с помощью волоконного лазера с добавкой полифениленсульфида и без. Изучены микроструктура полифениленсульфида, морфология поверхности раздела и сдвиговая прочность.
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| first_indexed | 2025-12-07T15:57:03Z |
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UDC 539.4
Shear Strength Optimization of Laser-Joined Polyphenylene Sulfide-Based
CFRTP and Stainless Steel
L. Y. Sheng,
a,1
F. Y. Wang,
b
Q. Wang,
b
and J. K. Jiao
b,2
a Shenzhen Institute, Peking University, Shenzhen, China
b Ningbo Institute of Materials Technology and Engineering, Chinese Academy of Sciences, Ningbo,
China
1 lysheng@yeah.net
2 jiaojunke@nimte.ac.cn
A thermosetting plastic and stainless steel were joined by the fiber laser with and without
polyphenylene sulfide (PPS) additive. Its microstructure, interface morphology, and shear strength
were investigated. The laser joining is shown to change the microstructure of the stainless steel and
result in the heat-affected zone and fusion zone, which contains the lathy ferrite and skeletal ferrite,
respectively. Without the PPS interlayer, the additive in the plastic can be overheated and
decomposed during laser joining, which is detrimental to the interface bonding. The additive can
contribute to the plastic and stainless steel interpenetration, but its amount should be controlled.
Insufficient additive quantities cannot fill the gap between stainless steel and plastic, but its higher
quantities can cause excessive melting, which would prevent from gaining the joint with optimum
shear strength. The appropriate interlayer thickness is 300 �m which improves the shear strength of
the stainless steel and plastic joint to 15.1 MPa.
Keywords: carbon-fiber-reinforced thermosetting plastic, stainless steel, laser joining,
polyphenylene sulfide, shear strength.
Introduction. Carbon fiber reinforced thermal polymer (CFRTP) is one of the
essential materials for structural applications, especially in aviation industries because of its
high strength to weight ratio [1]. However, in most applications, CFRTP always has to join
with metal frames to form complete structures, which plays a vital role in hybrid design.
Now, the common joining methods between the CFRTP and metal include the mechanical
joining, the adhesive bonding and the thermal joining [2]. The mechanical joining
technology has advantages of high joint strength and short-time processing, but it has some
drawbacks such as stress concentration and fiber damage [3]. The adhesive bonding
technology has a good fatigue life, low stress concentration, and corrosion resistance,
however, it has some weaknesses such as long curing time and bad environmental tolerance
[4]. The thermal joining method has better environmental adaptability compared with the
adhesion bonding method and has a more uniform stress distribution compared with the
mechanical joining. Therefore, the thermal joining has been considered the most suitable
technology for the joining of CFRTP and metal. Thermal joining methods include friction
welding [5], laser transmission welding [6], direct laser welding, etc. Among the methods,
the laser direct laser joining has attracted more attention, due to its advantages such as
high-efficiency, non-contacting, low thermal effect and suitable for opaque CFRTP.
Katayama and Kawahito [7] exhibited that the direct laser irradiates on stainless steel
could generate a Cr2O3 transition layer on the interface of plastic/stainless steel. Moreover,
the research of Tan et al. [8] revealed that the existence of Cr layer on the steel surface
enhanced the shear strength of the CFRP/steel joint by the Cr-O-PA6T bonding along joint
interface. Roesner et al. [9] demonstrated that the machined micro-grooves on the metal
surface increased the strength of laser joining plastic/aluminum joint to 24 MPa. Whatever
© L. Y. SHENG, F. Y. WANG, Q. WANG, J. K JIAO, 2018
ISSN 0556-171X. Ïðîáëåìè ì³öíîñò³, 2018, ¹ 5 153
the changing of processing parameter, surface morphology, and surface modification, air
bubbles are inevitably generated in the CFRTP. The study of Tan et al. [10] demonstrated
that the heat from the laser would result in rapid temperature increases, which could
generate the CO2, NH3, and H2O in the CFRP and promote the air bubbles and porosity.
Except for the investigation on the laser joining of the CFRTP and metal, the development
of the laser technology also encourages the application of laser joining of CFRTP and metal
[11]. Recently, we have joined the CFRTP and steel by the fiber laser, and it exhibited
relative good processibility [12]. Though the fiber laser could be applied in the joining of
CFRTP and metals, there are still many aspects that need to be investigated and clarified,
including processing parameters, interface, and fusion additive. However, the recent
researches mostly focused on the effect of processing parameters and bonding mechanism.
Almost no investigation has been carried out on the impact of fusion additive. Therefore,
the polyphenylene sulfide (PPS) additive having similar molecular structure with the
CFRTP matrix was chosen as the fusion additive in the present study. The laser joining of
CFRTP and stainless steel with different PPS additive thickness was conducted. The
microstructure, interface morphology, and mechanical properties of the CFRTP and stainless
steel joint were investigated.
1. Experimental Procedures. In the present study, the CFRTP panels with PPS
matrix reinforced by T700 carbon fibers were cut into the size of 50 30 3� � mm. The
CFRTP is composed by PPS matrix and 15 layers T700 carbon fibers, which is weaved
with intersected structure. The carbon fiber is wrapped by the PPS, and the average
thickness of the single layer is 0.2 mm. The 304 stainless steel specimens with a size of
50 30 2� � mm were prepared, and their surfaces for laser joining were ground by the 120#
abrasive paper to increase the roughness. The chemical composition of 304 stainless steel is
given in Table 1.
The joining of stainless steel and CFRTP was conducted by a fiber laser welding
system. This system comprises 1410RABB robot, 500 W fiber laser (continuous wave laser
machine and the wavelength is 1080 nm), laser processing head (the focal length is 120 mm),
air-actuated clamp and cooling system. The schematic diagram of the joining of stainless
steel and CFRP by the laser is shown in Fig. 1. Firstly, the CFRTP overlaid with PPS
additive on the surface was placed on the laser welding system and the stainless steel plate
was placed above the PPS additive. After then, the stainless steel, PPS additive, and CFRTP
were clamped by the air-actuated clamp which has a groove with a size of 60 10 5� � mm in
the upper one. The clamping pressure could be adjusted by controlling the air-actuator.
L. Y. Sheng, F. Y. Wang, Q. Wang, and J. K Jiao
154 ISSN 0556-171X. Ïðîáëåìè ì³öíîñò³, 2018, ¹ 5
T a b l e 1
The Chemical Composition of 304 Stainless Steel (wt.%)
C Mn Si Ni Cr S P Fe
0.07 0.78 0.56 8.10 18.33 0.006 0.032 Bal.
Fig. 1. The schematic diagram of stainless steel and CFRTP laser joint.
During the laser joining, the laser beam would scan on the surface of stainless steel in the
groove with the argon gas flow velocity of 30 l/min. To investigate the effect of the PPS
additive on the joint strength, the thickness of the PPS additive was changed gradually from
0 to 450 �m with the interval of 150 �m. The laser scanning speed, laser power, and
clamping pressure were set as 5 mm/s, 320 W, and 0.5 MPa, respectively. The detailed
changes in the processing parameter are listed in Table 2. In all laser-joined specimens, the
defocusing distance was �20 mm, and the laser beam diameter was 500 �m.
The microstructure and morphology of PPS additive, CFRTP and stainless steel and
CFRTP joint were characterized by the optical microscopy (OM), confocal laser scanning
microscope (CLSM), scanning electron microscopy (SEM) and tensile test. The specimen
for cross section observation was cut from the stainless steel and CFRTP joint and polished
by the conventional metallographic method. The KEYENCE VX-X200 CLSM was
employed to analyze the interface of the stainless steel and CFRTP joint. The Phenom Pro
SEM was used to observe the microstructure of laser scanned stainless steel and the
morphology of joint interface. The tensile test was performed on the UTM4304 electronic
universal testing machine to obtain the shear strength. The shear strength test was referred
to the GB/T7124-86 and ASTM F2255-2005(2010) standards. The tensile test was carried
out in the air with the initial strain rate of 2 10 3
�
� s�1 at room temperature. Three
specimens of the same condition were tested to obtain the shear strength data. The Stemi
2000 OM was applied to observe the debonding surface of the tensile specimen.
2. Results and Discussion.
2.1. The Microstructure of the CFRTP and PPS Additive. The typical
microstructures of PPS based CFRTP and PPS additive are shown in Fig. 2. The PPS based
CFRTP is mainly composed of black-grey carbon fiber and white-grey PPS matrix, as
shown in Fig. 2a. From the SEM image, it can be found that the carbon fibers are
overlapped layer by layer, and most carbon fibers are packed and bonded together by the
PPS. Based on the macroscopic observation, the layer of carbon fiber is weaved as
decussate structure. The layer of carbon fiber was about 200 �m in thickness, while some
layers of higher thickness were also observed. The observation of the layers of carbon
fibers revealed that they had the average size of 6 �m in diameter. Moreover, the
distribution of PPS in the CFRTP was not uniform, and the interface of the carbon fiber
layer preferably coincided with the PPS vacancies, while carbon fibers had good integrity
with the regular arrangement. The SEM observation on the PPS additive revealed that the
PPS fibers were overlapped randomly, and there was relatively high porosity, as shown in
Fig. 2b. Based on the SEM image, the PPS fibers had the average size of 20–30 �m in
diameter.
The macro- and micrographs of the laser-joined stainless steel and CFRTP are shown
in Fig. 3. The laser scanning results on the stainless steel, which exhibits an apparent
oxidation on the track of laser scanning, is shown in Fig. 3a. The observation on the
Shear Strength Optimization ...
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T a b l e 2
The Detailed Processing Parameters of Laser Joining Stainless Steel and CFRTP
Specimen Laser scanning
speed
(mm/s)
Laser power
(W)
Clamping pressure
(MPa)
Thickness of PPS
(�m)
S1 5 320 0.5 0
S2 5 320 0.5 150
S3 5 320 0.5 300
S4 5 320 0.5 450
interface of the laser-joined CFRTP and stainless steel reveals that CFRTP has a proper
bonding with the stainless steel even without the PPS additive, as shown in Fig. 3b. Such a
joined state should be attributed to the existence of PPS in the CFRTP. During the laser
joining, the laser scanning on the stainless steel would increase the temperature of the steel
surface to about 400�C, which could melt the PPS to liquid and spread on the gap of
stainless steel and CFRTP [13]. Due to the limited amount of PPS in the CFRTP, the melted
PPS could not spread over the gap uniformly. The addition of PPS additive would solve this
problem, as shown in Fig. 3c. It can be seen that the molten PPS has filled the gap of steel
and CFRTP. Moreover, some molten PPS additive flow get out of the gap and spread over
the adjacent stainless steel, but its distribution is not even. The observation on the laser
scanned stainless steel revealed that the laser scanning strongly influenced the stainless
steel microstructure, as shown in Fig. 3d. There are fusion zone and heat-affect zone (HAZ)
in the steel, which have semi-ellipsoidal shapes. In HAZ, the lathy ferrite mainly precipitates
along the original grain boundary or twin boundary, which separates the original grain and
refines the structure, as shown in Fig. 3e. Moreover, a distinct boundary is formed between
156 ISSN 0556-171X. Ïðîáëåìè ì³öíîñò³, 2018, ¹ 5
L. Y. Sheng, F. Y. Wang, Q. Wang, and J. K Jiao
Fig. 2. Morphology of CFRTP with the overlapping of carbon fibers (a) and PPS additive (b).
Fig. 3. (a) Macrograph of the laser joined CFRP and stainless steel; (b) morphology of the CFRP on
the stainless steel without PPS additive; (c) morphology of the CFRP on the stainless steel with PPS
additive; (d) microstructure of the laser-scanned stainless steel; (e) lathy ferrite and skeletal ferrite in
the heat-affected zone; (f) skeletal ferrite and cellular austenite in the fusion zone.
HAZ and matrix. With the observation proceeding to the fusion zone, the ferrite becomes
coarse and increases, which forms the skeletal structure, as shown in Fig. 3f. There is no
distinct boundary between HAZ and the fusion zone. The latter zone is mainly
distinguished by the morphology and amount of the ferrite [14]. In the fusion zone, the
skeletal ferrite and cellular austenite are the main ingredients. Based on findings [15–18],
the higher cooling rate results in the formation of cellular structure. In the present study, a
relatively high Cr content and high laser scanning speed are shown to promote the
formation of ferrite with intercellular or interdendritic structures.
The shear strength of the stainless steel/CFRTP joints was tested to evaluate the effect
of PPS additive on the interface bonding. The shear strength of the stainless steel/CFRTP
joints with different PPS share is depicted in Fig. 4. It can be seen that the shear strength of
the stainless steel/CFRTP joint without PPS additive is about 7 MPa. A small addition of
PPS improves the shear strength of the stainless steel/CFRTP joint, which reaches 9.3 MPa.
The shear strength of the stainless steel/CFRTP joint attains the maximum value of 15.1 MPa
when the PPS thickness is about 300 �m. Noteworthy is that the shear strength of the
stainless steel/CFRTP joint drops significantly to 3.9 MPa, when the PPS thickness is
450 �m. Such variation trend of the shear strength of the stainless steel/CFRTP joint
strongly indicates that the PPS additive is instrumental to enhance the adhesive strength
between the stainless steel and CFRTP, but its amount should be controlled.
The observations on the debonding surface of the stainless steel/CFRTP joints with
different thickness of PPS additive are shown in Fig. 5. It can be found that the CFRTP still
can be joined with the stainless steel without PPS additive, as shown in Fig. 5a. Due to the
woven structure of CFRPT, the distribution of melted PPS over the surface of stainless steel
is not homogeneous. Moreover, the decomposition of PPS in CFRTP can be observed on
the debonding surface of CFRTP. When the thickness of PPS additive increases to 150 �m,
the melted PPS additive attached to the surface of stainless steel is thin, as shown in Fig. 5b.
Furthermore, the melted PPS additive fills in the vacancy of the CFRTP surface, but such a
thickness of PPS additive is not enough to spread and merge with the PPS matrix of CFRTP
thoroughly. Therefore, the joint with 150 �m-thick PPS additive has some fiber exfoliation
morphology and a relatively low shear strength. On the debonding surface of stainless
steel/CFRTP joint with 300 �m PPS additive, one can observe that PPS additive is melted
and adhered to the stainless steel surface perfectly, as shown in Fig. 5c. A layer of carbon
ISSN 0556-171X. Ïðîáëåìè ì³öíîñò³, 2018, ¹ 5 157
Shear Strength Optimization ...
Fig. 4. The shear strength of the stainless steel/CFRTP joints with different thickness of PPS
additive.
fiber is exfoliated from the CFRTP and adhered on the CFRTP uniformly, which suggests
the PPS additive has good bonding with the stainless steel. With the thickness of PPS
additive increased to 450 �m, it adheres to the stainless steel, but the CFRTP surface has
almost no melting features, as shown in Fig. 5d.
As shown in Fig. 6, the observation on the interface of stainless steel/CFRTP joints
with different thickness of PPS additive exhibits that any addition of PPS additive would
result in the formation of air bubbles. When the thickness of the PPS additive is 150 �m, air
bubble are regularly distributed over the joint interface, as shown in Fig. 6a. Based on the
recent research [13], the formation of this kind of air bubbles should be ascribed to the
decomposition of PPS induced by the excessive heat generation. With the thickness of PPS
additive increased to 300 �m, the interface has the residual PPS and a few air bubbles, as
shown in Fig. 6b. The reduced decomposition implies that the heat transfer is sufficient for
the melting of PPS additive. However, on the interface of joint with 450 �m PPS additive,
there are many air bubbles, and they prefer to aggregate, as shown in Fig. 6c. Such a
phenomenon should be attributed to the insufficient heat transfer. Due to the increased PPS
additive, the transferred heat is insufficient for melting the PPS thoroughly to obtain a good
fluidity. The residual air in the interface is not removed, which promotes the formation of
aggregated air bubbles.
Based on available findings [19, 20], the joining of the dissimilar materials mainly
depends on the initial interface bonding. In the present paper, the initial interface bonding is
determined by the PPS, which fuses the CFRTP and stainless steel. However, the PPS state
during the laser joining is influenced by the processing parameters and thickness of PPS
additive [13]. Given that heat transfer from the laser is controlled in this study, PSS
thickness determines the fusion of PPS additive. If the amount of PPS additive is too small,
it may be overheated and decomposed, which would hinder the coalescence of stainless
steel and CFRTP. If the amount of PPS additive is too high, it would fail to melt thoroughly
and fill the gap between stainless steel and CFRTP effectively. Therefore, one can find that
158 ISSN 0556-171X. Ïðîáëåìè ì³öíîñò³, 2018, ¹ 5
L. Y. Sheng, F. Y. Wang, Q. Wang, and J. K Jiao
Fig. 5. The morphology of debonding surface of the stainless steel/CFRTP joints with different PPS
addition thickness after tensile: (a) 0 �m, (b) 150 �m, (c) 300 �m, and (d) 450 �m.
there are apparent vacancies or air bubbles in the interface of stainless steel and CFRTP
joint with some PPS additive. Thus, the addition of PPS should be controlled, to ensure that
it would melt thoroughly and fill the gap between stainless steel and CFRTP. In the present
study, the optimal thickness of PPS additive was found to be 300 �m, which corresponded
to the best bonding interface and shear strength of stainless steel/CFRTP joint.
C o n c l u s i o n s
1. CFRTP/304 stainless steel laser joints were produced with and without PPS
additive. Without the PPS additive, the PPS in CFRTP could be overheated and decomposed,
which is detrimental to the interface bonding. However, the addition of PPS additive was
found to improve the CFRTP and stainless steel bonding strength.
2. The laser joining produced the fusion zone and heat-affected zone (HAZ) in
stainless steel. In HAZ, the lathy ferrite precipitates along the boundary, which refines the
austenite. In the fusion zone, the ferrite forms the skeletal structure and separates the
austenite into a small cellular structure.
3. The shear strength of the stainless steel and CFRTP joint can be improved by
adding the appropriate amount of PPS additive. Its maximum value of 15.1 MPa was
reached when the PPS thickness was 300 �m. Higher or lower PPS thickness values
resulted in lower shear strength of the stainless steel/CFRTP joint.
Acknowledgments. The authors are grateful to the support of Shenzhen Basic Research
Project (JCYJ20150529162228734, JCYJ20160427100211076, JCYJ20160427170611414,
JCYJ20150625155931806, and JCYJ20170306141506805).
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Fig. 6. The interface morphology of the stainless steel/CFRTP joints with different PPS addition
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Received 05. 03. 2018
160 ISSN 0556-171X. Ïðîáëåìè ì³öíîñò³, 2018, ¹ 5
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| id | nasplib_isofts_kiev_ua-123456789-174002 |
| institution | Digital Library of Periodicals of National Academy of Sciences of Ukraine |
| issn | 0556-171X |
| language | English |
| last_indexed | 2025-12-07T15:57:03Z |
| publishDate | 2018 |
| publisher | Інститут проблем міцності ім. Г.С. Писаренко НАН України |
| record_format | dspace |
| spelling | Sheng, L.Y. Wang, F.Y. Wang, Q. Jiao, J.K. 2020-12-28T19:17:27Z 2020-12-28T19:17:27Z 2018 Shear Strength Optimization of Laser-Joined Polyphenylene Sulfide-Based CFRTP and Stainless Steel / L.Y. Sheng, F.Y. Wang, Q. Wang, J.K. Jiao // Проблемы прочности. — 2018. — № 5. — С. 153-160. — Бібліогр.: 20 назв. — англ. 0556-171X https://nasplib.isofts.kiev.ua/handle/123456789/174002 539.4 A thermosetting plastic and stainless steel were joined by the fiber laser with and without polyphenylene sulfide (PPS) additive. Its microstructure, interface morphology, and shear strength were investigated. Исследовано соединение термопласта, армированного углеродным волокном, и нержавеющей стали с помощью волоконного лазера с добавкой полифениленсульфида и без. Изучены микроструктура полифениленсульфида, морфология поверхности раздела и сдвиговая прочность. The authors are grateful to the support of Shenzhen Basic Research Project (JCYJ20150529162228734, JCYJ20160427100211076, JCYJ20160427170611414, JCYJ20150625155931806, and JCYJ20170306141506805). en Інститут проблем міцності ім. Г.С. Писаренко НАН України Проблемы прочности Научно-технический раздел Shear Strength Optimization of Laser-Joined Polyphenylene Sulfide-Based CFRTP and Stainless Steel Оптимизация сдвиговой прочности лазерного соединения термопласта на основе полифснилснсульфида, армированного углеродным волокном, и нержавеющей стали (на англ, яз.) Article published earlier |
| spellingShingle | Shear Strength Optimization of Laser-Joined Polyphenylene Sulfide-Based CFRTP and Stainless Steel Sheng, L.Y. Wang, F.Y. Wang, Q. Jiao, J.K. Научно-технический раздел |
| title | Shear Strength Optimization of Laser-Joined Polyphenylene Sulfide-Based CFRTP and Stainless Steel |
| title_alt | Оптимизация сдвиговой прочности лазерного соединения термопласта на основе полифснилснсульфида, армированного углеродным волокном, и нержавеющей стали (на англ, яз.) |
| title_full | Shear Strength Optimization of Laser-Joined Polyphenylene Sulfide-Based CFRTP and Stainless Steel |
| title_fullStr | Shear Strength Optimization of Laser-Joined Polyphenylene Sulfide-Based CFRTP and Stainless Steel |
| title_full_unstemmed | Shear Strength Optimization of Laser-Joined Polyphenylene Sulfide-Based CFRTP and Stainless Steel |
| title_short | Shear Strength Optimization of Laser-Joined Polyphenylene Sulfide-Based CFRTP and Stainless Steel |
| title_sort | shear strength optimization of laser-joined polyphenylene sulfide-based cfrtp and stainless steel |
| topic | Научно-технический раздел |
| topic_facet | Научно-технический раздел |
| url | https://nasplib.isofts.kiev.ua/handle/123456789/174002 |
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